Mold and mold form



Oct. v13, 194:2.'v H. F. HAGEMEYER 2,299,016

' MOLD AND MOLD FORM I Original Filed Juge 14, 1938 2 Sheets- Sheet i 3'C122 E +13 :,21v I l 11kg@ 20 g D 13 z2 t 10 l l 1 W@ l Y//A/////// L E1 710 '12 l v I Oct- 13,1942- i `l-l. F. HAGEMEYER 2,299,016'

. MLD AND MOLD FORM A Original 'Filed June 14. 19,38 2 Sheets-Sheet 2Zyl/,2.

iQ-vga @ya W2-P v ndex/Z071 ffqgmgef Patented Oct. 13, 1942 MOLD ANDMOLD FORM Henry F. Hagemeyer, Chicago, Castings Patent Corporation,corporation of Illinois IIL, assignor to Chicago, 111.', a

original' application June 14, 193s, serial No.

1940, Serial N0. 328,215

Claims (Ci. 2z-.113)

My invention pertains to molds for use in making metal castings. of mycopending application Serial No. 213,595, filed Jue 14, 1938, andentitled Molds and mold forms.

In conventional casting practice, where a con- 'Ihis application is adivision tinually charging variety of castings is made in small lots,the match plates used for only one job and then discarded are a sourceof considerable expense.A Such match plates are relatively costlybecause they must be machined accurately to provide a true partingsurface on each mold section. Heretofore it has been customary to aiilxthe individual patterns directly to the match plate, so that it can beused with no other pattern group and becomes obsolete when the run ofits particular group of castings is completed, because of the holesdrilled -therein to receive screws for securing the patterns to it. Itis extremely infrequent'v that a repeat order'I will be received at thesame time, for equal quantities of all castings corresponding to thepatterns on a match plate. A choice must be made, therefore, betweendevoting a whole match plate to one type of pattern, which usually isnot warranted by the quantity of units required, or by shifting patternsfor castings a larger number of which is required to new match plateswith a different pattern assembly, when the quantity of castingscorresponding to some of the patterns on the match plate has been made.The old match plates are then discarded and the patterns whose jobs arefinished are removed from such match plates andstored.

I have devised a match plate assembly which employs a plurality ofindividual pattern plates, each carrying a pattern, which may bevassembled in parquet fashion on a base plate. These unit pattern platesare all of the same size, or in size a simple multiple of the smallestpattern plate, so that a selected group of such plates can be assembledonto a base plate of standard size adapted to accommodate apredetermined-'number of unit pattern plates of the smallest size. Suchassembly will, of course, exactly cover the entire pattern platereceivirg surface of the base plate,

A further diiliculty arises in conventional practice inthe assembly ofthe mold sections, Occa'' sionally there are parts of a mold sectionprojecting beyond the general plane of the parting surface; f orexample, there may be dowels of a dowel and socket registeringarrangement. When the mold sections .are being placed together theparting surfaces are hidden from view,and it is diiiicult totell whetherthe corresponding parts of the sections are in exact registry as thesections Divided and this application April A6,

approach each other. Mold material, such as that of the gypsum basetype, :for example, is quite fragile and if a projecting part of onemold section is not in precisealignment with its complemental recess inthe other mold section, either the projection, or the surface of theother mold section accidentally struck by such projection, or both, maybe damaged. Even an injury only to a dowel may be serious, for itspurpose is to prevent misalignment of the adjoining mold sections sothat an accurate casting, rather than a lopsided one, will be producedby the metal poured into the mold cavity.

To insure accurate positioning of the mold sections during theassembling operation, I have devised registering elements for theiredges which may be engaged by a suitable guiding device prior to contactof their parting surfaces; This mechanism will guide the movement of themold s ections as they approach engagement and -preferably also willsupport at least 4one of such sections during such operation. Theregistering element may consist of ribs, one on each of two oppositeedges of each mold section, lar to ,the parting surface and so disposed'that the cope ribs will be aligned with the drag ribs when the moldsections are assembled. The cope ribs may be provided with shouldersintermediate ktheir-ends which may be employed in supporting the cope.

mold form tovform metal receiving mold cavities,

A further consideration in the design of my and mold is to provide meansfor eliminating the dns on the castings, and also on' the feeders forthe molten metal, such as the runv xner and gates. For this purpose Iprovide a groove about each mold cavity pattern to producel -a sealingridge along the margin of each moldcavity. By the term mold cavitypattern I refer to all patterns on the match plate which serve includingthe runner pattern strip. gate pattern strips, sprue pattern post, inaddition to those patterns which form the cavities for production of theuseful castings. 1

'I'he principal object of my invention, therefore, is to provide a matchplate assembly having a plurality of interchangeable pattern plates allof'a uniform size, or thesize of each of which is'.

smallest pattern'plate.-

a simple multiple of the which may be assembled to. cover a baselparquet fashion.

yl'i further object is to provide such a match plateA assembly in whichthe runner and sprue Plate in v cavityforming portions of the patternneed not and preferably also the patterns for extending perpendicuandsections will remainxed when the pattern plates are interchanged.

Still another object is to provide -means for forming on the moldsections during the molding operation registering elements for use inguiding complemental mold sections while they are being assembled toform the complete mold.

A further object is to provide means for pre- I venting the formation offins on the useful castings and also on the feeders, such as the runnersand gates.

Additional objects, and especially those resulting from the particularconstruction of my flask and match plate assembly, will be understoodfrom a study of the following detailed description in conjunction withthe. accompanying drawings. I have illustrated a ask rim or ring andmatch plate assembly which I have found to be practical, but obviouslymany variations may be made in its structural details within the spiritof my invention as dened in the claims appended to this specification.

Fig. l is a plan view of the cope nasi: rim and match plate assemblyshowing a representative casting pattern mounted on a pattern plate.'

Fig. 2 is a'transverse section taken along line 2 2 ofvFig. 1.

Fig. 3 is a fragmentary longitudinal section taken along line 3 3 ofFig. l. y

Fig. 4 isl a fragmentary longitudinal section taken along line (fi-d ofFig. i.

Fig. 5 is a fragmentary transverse section taken along hne 5 5 ofFig. 1. i

Fig. 6 is a fragmentary longitudinal section corresponding to Fig. 6.-,but illustrating the drag ask rim and match plate assembly.

Fig. 7 is a fragmentary transverse section taken' along hne 'll- 1 ofFig. 6.

Fig. 8 is a fragmentary central longitudinal section through assembledcope and drag moid sections.

Fig. 9 is a fragmentary transverse section at the position of line Ill-I0 of Fig. 8, showing the mold sections just prior to their engagement.

Fig. 10 is a fragmentary' transverse section through assembled cope anddrag mold sections taken along line AIIL-Ill of Fig. 8.

Fig. 11 is afragmentary perspective view 4oi. the drag mold sectionshowing the projecting rib used to assist in guiding it during the.operation of assembling the cope and drag mold sections into thecomplete mold.

Fig. 12 is a plan view of a representative cast'- ing.

Fig. 13 is an elevation View of the casting of Fig. 12.

Fig. 14 is a. fragmentary plan view of one mold section employed informing the casting of Fig. 12.

Fig. 15 is a transverse section taken on line4 I5--I5 of Fig. 14. Y

Fig. 16 is a fragmentary transverse section tak. en on line It-I6 ofFig. l, and showing the pa-ttern employed in forming the mold section ofFig. 14. l

Fig. 17 is an Venlarged fragmentary section through cope and drag moldsections showing complemental sealing ridges just prior to their`engagement during the operation of assembling the mold sections.

Fig. 18 is 'a fragmentary section through-cope' and drag mold sectionsshowing they sealing ridgesof Fig. 17 after being pressed intoengagement.

' forming dowels and dowel sockets for the mold Fig. 19 is a fragmentarysection through conventional cope and drag mold sections in the regionof a mold cavity edge just prior to engagement of their parting surfacesduring the operation of assembling the mold sections.

Fig. 20 is a fragmentary section similar to Fig. 19 showing the partingsurfaces pressed into engagement.

Fig. 21 is a fragmentary se'ction through cope and drag mold sectionssimilar to Fig. i7, but showing a modified form of sealing ridge.

Fig'. 22 is a fragmentary section through that portion of a matchplate-and pattern employed to forinon a mold section a sealing ridgelike that shown in Fig. 2l.

Fig. 23 is a fragmentary section through that portion of a match plateand pattern for forming a still further shape of sealing ridge.

Fig. 24 isa fragmentary section through cope and drag mold sectionslsimilar to Fig. 1'7, but showing the sealing ridge on only one moldsection. V

In the match plate and flask assemblies shown in Figs. 1 to 7,inclusive, the .individual pattern some useful casting pattern P, aremounted in y parquet fashion on a base plate i, which extends preferablybeyond all the elements assembled thereonl Thus the entire pattern platereceiving area of base plate I will be covered by edge-ad-r joiningpattern plates. These pattern plates may all be uniform in size, or iflarger plates are re- `quired to accommodate certain patterns, they maybe made double the size of the smallest plate iii, as indicated by ID',or the size may be even three or four times the size of the minimumplate. Preferably the length of all the plates between the center plateI I anda marginal plate.I2 is the same, although the widths of differentsized plates, parallel to thecenter plate II, may vary in simplemultiples of the width of the narrowest plate. These pattern plates may,therefore, all be said tofbe in width a. simple multiple of the smallestplate size, the term simple multipie including unity, to embrace thesituation where all the plates are of the same size.

On each pattern platev will be mounted permanently a useful castingpattern, and when the presently required number of molds have been'stituting operation. ,The flask rim and match plate structure is suchthat evena complete interchange of the individual pattern plates may bemade without disturbing any of the uniformly necessary elements such'asthe flask rim, sprue post, and main runner pattern, which remainpermanently secured to the base plate i.

Moreover all pattern platespf the same size are provided with uniform.meansfor securing them to the base plate I, which may consist of dowelsI3 carried by two diagonally opposite corners of the pattern plate andengageable in holes formed in the base plate I. Into the otherdiagonally opposite corners may be screwed bolts I4 extending throughthe base plate I which is recessed to receive the bolt heads. A furthersimillax; holding bolt may be provided at'the center of each patternplate. The disposition of the dowand both ends of which els and boltreceiving apertures will. of course, correspond on each of the patternplates no matter what the plate width may be. In each of the variouspattern plate positions of the base plate I the screw and dowel holeswill be arranged in the same relative positions.

The center plate II and the marginal plates, I2 may be permanentlysecured to the base plate I in any suitable manner. A ilask rim or ring2 may also vbe secured in permanent relationship to the match plate,preferably resting on the marginal plates I2. n the center plate II arunner pattern strip I5, shorter-than the center plate, is mounted,which'may be the same shape and size for both the cope and drag matchplates, stop short of the rim 2. I prefer, however, that the runnerpattern'in the cope match plate be higher than that in the drag matchplate, to allow any dross which may flow into the runner cavity toaccumulate in the upper portion thereof above branch gatesl provided inthe cope mold section. In the cope match plate a sprue pattern post I5is also provided, preferably located at one end of the runner patternI5. The runner pattern of the drag also has a sprue pattern projectionI1 which produces a sprue 'sump '1n the drag section of the moldimmediately belowv the sprueaperture in the cope section of the mold.

Between each end of the center plate II and the adjacent end of therunner pattern I5, I provide means constituting arpattern for either thedowel or the socket of a dowel and socket mold section registeringdevice. Preferably in the cope match platea boss I8 is provided to serveas a pattern for forming a dowel socket in the cope mold section. In thedrag match plate assembly, on the other hand, will be provided a cup I9,of slightly less depth'than the height of boss IB, serving as a patternfor a dowel complemental to the dowel socket formed in the cope moldsection. It will, therefore, be seen that the patterns for forming thedowel registering mechanism, the runner cavity, the sprue aperture, andthe sprue sump are all permanently secured lto the base plate I, and areentirely separate from and mounted independently ofthe interchangeablepattern plates I0 and I0. n

The manner in which the cope and drag mold sections iit together isillustrated in Fig. 8, in which the cope section C is provided with thevsprue aperture I6' and a portion of the runner cavity I5', whereas .thedragsection D has the sprue sump I1', located immediately below thesprue aperture I6', and the remainder of the runner cavity I5', Thesprue aperture and sumpI as well as the portions of the runner cavityand complemental mold cavities formed in other portions of the cope anddrag, are held in registry by the dowels Il' of the drag seated in thedowel sockets I8' provided 1n the cope. The purpose of the sprue sump l1is to prevent the molten metal from rushing violently and in a pulsatingfashion into land throughthe runner cavity Il', and from there into theuseful casting forming portions of the mold cavity. As the metal owsthrough the aperture I8 into the sprue sump I'I'I its inrushing force issomewhat absorbed by the impact and turbulence therein, and its flowbecomes consolidated and smooth as it enters thel runner cavity.

After each mold cavity corresponding to a useful casting has been filledwith molten metal it' is desirable to provide -a reservoir of metal fromwhich the metal of the casting may draw as it' shrinks during theprocess of solidication and cooling, and which reservoir willremainliquid ,until such action is substantially complete. If no source ofmolten metal is provided, from which the deciency caused by suchshrinkage may be made up, excessive strains will be set up in the finalcasting, and a strong, solid casting may not result. For convenience thereservoir of molten metal should be the feeders, namely, the gates, therunner, and the sprue, all of which should be of suilicient size and ofproper shape to remain liquid and to supply metal to rell all thecasting mold cavities as the metal therein progressively 'shrinks insolidifying and cooling. In order to maintain all these feeders in aliquid condition, theoretically their surfaces, which radiate heat,should be kept to a minimum. Their cross sections should, therefore, becircular, but since it is inconvenient to make these feeders preciselycylindrical while making them large enough, at least their cornersshould be rounded as indicated in the runnerv cavity I5' of Fig. 8.

The heat radiation of anyl such feeder will be greatly increased, whichwill correspondingly in- -crease its' cooling rate andhastensolidification, by the formation thereon of a fine between the partingsurfaces of adjoining mold sections.

Such fins frequently occur on the runner and gates which are almostinvariably located at the parting surfaces. The crevice in the seamformed by the junction of the parting surfaces along these feeders, asshown in Fig. 20, I have found can be sealed by the provision of asealing ridge 3 as shown in Fig. 9. Such ridge is produced by forming agroove 3' along the sides of the patterns forthe feeders, such as thegate pattern strip G and the runner pattern strip I5.

In the preferred construction, the groove 3' for the gate pattern stripG is formed directly in the pattern plate I0, on which such strip ismounted, depressed below the surface of such pattern plate. A marginalgroove 3 may be formed along the runner pattern strip I5 between eachside thereof and the adjacent edgeof a pattern plate merely by makingthe-longitudinal edges of center plate II of a thickness slightly lessthan the thickness-of the abutting pattern -plate I0 or I0'. The actionof the sealing ridges 3 is illustrated in Figs. 9 and l0, the formerfigure showing the cope and drag mold sections C and D, respectively,just prior to engagement of their parting surfaces,.while Fig. l0 showsthe saine portions of the cope and drag sections after their pantingsurfaces have been pressedv into engagement. Eac'hg'roove 3 may4advantageously be approximately one-sixteenth of an inch in width andthree-thousandths of an in-ch in depth, so that. the sealing ridges 3will .be approximately one-sixteenth of an inchv in width andthreethousandths of an inch in height. The mold material is preferablyof a crushable nature such, for example, as of gypsum base, so that whentheparting surfaces are pressed together, the

sealing ridges will be engaged before the remainder of the partingsurface comes into contact, and their crests will be forced inward and ydeformed until theylie substantially in the-.plane -of the partingsurfaces. This operation will prostill another shape.

It is also desirable in many instances to provide a similar sealingridge about part or all of the cavity in which the nished casting is tobe formed. The sealing action of the ridges is the same here as whenprovided along the feeder cavities, but, the considerations makingelimination of the iin desirable are different. Unflnned feeders, as hasbeen pointed out, have less radiation surface and hence are lesssusceptible to chilling and rapid solidiiication, so that they willremain liquid until the metal forming the iinished castings hassolidified and cooled. Fins on usable castings, however, are undesirablebecause eXtra grinding or machining of such castings is required toremove them during the finishing operation. A representative sample ofan unfinned casting is shown in Figs. 12 and 13, and one section of themold used in the casting operation therefor is illustrated in Figs. 14and 15. Figs. 1 and 16 show the pattern P by which the moldfsection ofFigs. 14 and 15 is formed. In the pattern plate iii, encircling thepattern F, or in the inserted pattern block, as shown in `Fig. 16, is

` provided a marginal sealing ridge pattern in the form of a groove 3 bywhich the sealing ridge t for the castingcavity is formed on the mold.In

Fig. 14 are also shown the ridges 2 along the sides of the gate cavityG.

A comparison of the engagement of the sealing ridges and the engagementof conventional parting surfaces adjacent to a mold cavity isillustrated in the contrast of Figs. 17 and i8 with Figs. 19 and 20,these figures being much enlarged. A conventional pattern mounted in amatch plate ordinarily has a slight fillet about its base, so that theparting surface of a mold section meets the adjacent side of a moldcavity in a slight arc. As a result, when the mold sections of Fig. 19have their parting .surfaces broughtinto engagement, as shown in Fig.v20, a slight recess or crevice is formed into which the metal flows asit lls the mold cavity. The wedging action ofthe molten metal enteringthis crevice tends to force the mold sections apart, allowing a sheet ofmetal to flow between the parting surfaces, and thereby producing a fin.On the other hand, even though the parting surfaces of sealing ridges 3of Fig. 17 may form an arcuate junction with the adjacent sides of themold cavity, when these ridges are pressed together, as shown in Fig.18, the crushable material will be deformed and forced laterally to fillup any crevice at the junction between the parting surfaces. Hence the`metal flowing into the cavity has no matrix for the formation of anentering wedge between the contacting parting surfaces of the moldsections.

It is not necessary that the sealing ridge have a flat crest such asshown in Fig. 17. An alternative form is illustrated in Fig. 21 havingthe crest of the ridge substantially in prolongation of the wall of themold cavity. 'I'he ridge then slopes from this crest away from the moldcavity to merge with the main parting surface. Fig. 22

c illustrates a portion-of a mold cavity pattern having a marginalpattern provided with a groove of a shape to form the sealing ridge ofFig. 21. Fig. 23 shows a pattern for forming a sealing ridge of In bothof these latter shapes the compression of the mold material will begreatest at the side of the ridge adjacent to the mold cavity, as themold sections are pressed together.' It is not even always necessarythat the sealing ridge be formed on the parting surfaces of both thecope and the drag, for a ridge on one parting surface only, as shown inFig. 24,

may be sumcient. Especially if the cavity for a casting is formedentirely in one mold section, the other section having an unbrokenparting surface extending on both sides of the sealing ridge, asindicated by the broken line showing of Fig. 24, a single ridge issufficient. It is merely necessary that the material of the sealingridge or ridges, when crushed, fill any crevice between the partingsurfaces of the mold sections and pack suiiiciently tightly-at theirjunction to prevent any metal owing from a mold cavity outward betweenthem.

Especially whenl the parting surfaces of both the cope and drag moldsections are provided withmutually engageable sealing ridges, it isextremely desirable that the mold sections be so disposed in registryprior to their assembly'that there will be no lateral movement of theparting surfaces and ridges at the time of their contact, causingrubbing which would tend to fracture and perhaps shear off into the moldcavity a portion of the ridge material, which would contaminate themetal poured into the mold cavity. Some provision should, therefore, bemade to confine the mold sections to strictly linear movement as theirparting surfaces approach each other during the assembling operation.For this purpose I provide mold section registering elements on eachmold section, such, for example, as the ribs 4 formed on each end ofeach mold section generally perpendicular to their respective partingsurfaces, as shown in Figs. 8 and 11. Preferably each rib, immediatelyadjacent to the parting surface of the mold, has a portion 40, providedwith side and end faces in planes precisely normal to the partingsurface, the two side faces, moreover, being parallel. The ribs arecomplementally located and aligned so that the side' and end surfaces ofthe portions 40 on the respective ends of the cope and drag moldsections are in coplanar relationship. Between the portion 40 'of eachrib 4 and the flared portion 4| thereof, a shoulder 42, projectingbeyond both the sides and end of the portion 40, is provided, whichshould be of suflicient Width to enable the mold section to be supportedby a device only in engagement with such shoulder. As the mold sectionsapproach each other, therefore, suitable means should be provided tomaintain the sides of the portions 40 on the corresponding cope and dragribs 4 in coplanar relationship as 'the parting surfaces are broughtinto engagement.

A convenient method of forming the ribs 4 is to provide pattern recesses20 in the wall of the flask ring or rim 2. To increase the accuracy ofthe registering operation, the sides of the portion 40 of each rib 4should be formed to precise dimensions and shape. These factors may bemore easily controlled if the recess in the flask yis provided with aseparate pattern block 2| accurately iiask rim 2 is provided with anotch in its lower edge of proper width and depth to fit snugly over thepattern block 2 I. For forming the portion 4| yof each rib 4 of a sizeto leave the intermediate shoulder 42 between the ends of the rib, theportion of groove or recess 20 in the flask rim proper remote from thebase plate should be wider and deeper than the groove 22 in the block2l, but should be in alignment with such groove. When located in properlateral relationship by the blocks 2l tted within its grooves the flaskrim 2 may be secured permanently to the base plate I by any suitablemeans. As is evident from Fig. l, I

the pattern plates I0 or l0 may be removed from .t or inserted into thematch plate assembly Without removing the iiask ring ordisturbing thelocation of the blocks 2| which are secured to the marginal plates i2.

Having described the preferred embodiment of my invention, what I claimas new and useful and desire to protect by United States Letters Patent,

1. A mold section having a metal receiving cavity below the generallyplane parting surface thereof, and -a slight crushable ridge upstandingabove the lparting surface and extending along the peripheral edge ofsuch cavity, said ridge adapted to be crushed when the mold is assembledto form a portion of mold material of greater density.

2. A` mold section having a metal receiving.

cavity below the generally plane parting surface thereof, and a slightcrushable ridge having a flat crest substantially parallel to suchparting surface and of much greater width than height upstanding abovethe parting surface and extending along the edge immediately adjacentsuch cavity, said ridge adapted to be crushed when the mold .isassembled to form a portion of mold material of greater density.

tending along the peripheral edge of such cavity,

and said ribs being adapted mutually to crush v each other toform asection of mold material of f greater density when said mold isassembled.

4. A mold comprising a pair of cooperating mold sectionswhich whenplaced face to face enclose a mold cavity, and means to prevent theformation of a iin at the parting line between said sections, comprisinga ridge formed as a portion of at least one of said sections andextending beyond the parting surface thereof, said ridge out'- liningsaid cavity,' said'ridge being adapted to be crushedvhen the partingsurfaces of said sections arev brought together, and said crushed ridgevforming a. portion of.l mold material -of greater density than adjacentmold material,

5. The method of preventing the formation of a n at the parting line ofa casting which comprises forming a mold having a casting impressiontherein, forming a ridge on said mold outlining said casting impression,and crushing said ridge while assembling said mold to provide a moldportion of greater density at the mold parting line.

-HENRY F. HAGEi/mirm

